Cap



Aug. 29, 1967 s. LIPKIN 3,337,877

Filed July 19, 1965 y4 sheets-smet 1 FIG. 7

INVENTOR SOA. ,/Pe/A/ S. LIPKIN Aug. 29, 1967 GAP 4 Sheets-Sheet 2 Filed July 19, 1965 FIG. 9

FIG. IO

INVENTOR 50A, Awe/Af 6 Afro/@vaas sim S. LIPKIN Aug. 29, 1967 CAP 4 Sheets-Sheet I5 Filed July 19, 1965 FIG. Il

INVENTOR SOA /C//K//t/ BY y/7% #am 677064/55/5 Aug. 29, 1967 s. I IPKIN, y 3,337,877

y CAP Filed July 19, 1965 4 sheetsfsheet 4 1f/ew INVENTOR 50A, ,/P/Z/A/ United States Patent O 3,337,877 CAP This invention relates to an improved cap construction and particularly to improvements in lighter weight spring, fall and summer caps of tailored construction which are comfortable, attractive in appearance, which it the wearer snugly, and, where desired, can be provided with ear aps to provide ear protection as for winter caps. The invention particularly relates to tailored cap structures which can be manufactured in a fewer number of sizes and caps of standard construction.

When the retail purchaser buys a cap, this is the consummation of a long series of prior events. These events begin with the design of the cap. The construction of one cap is of no great diculty, but when a manufacturer designs a cap which is to be sold in retail stores, if the cap is to be sold in reasonable quantities, it must be stocked by the retail store in a range of sizes sutlicient to lit a large number of head sizes, and in a range of styles and colors. Caps are sold in sizes which are divided into three major classifications, namely, mens, boys and junior boys sizes. Mens sizes range from 6% to 7% and require a total of nine sizes. Boys sizes range from 6% through 7%; and require a total of seven sizes. Junior boys sizes range from 6 through 6% and require a total of seven sizes. Therefore, a stock of caps, of only one `color and style, and one cap per size, would involve a total of 23 caps. When several colors are stocked, as well as duplicates in the more popular sizes, the merchants total number of caps in stock can easily exceed 100 caps, for one style only. If several styles and several colors in each style are stocked, then the number of caps increases accordingly.

Therefore, the stocking of merchandise at retail in order adequately to serve the retail customer, involves a considerable investment for every retail store at which cap merchandise is sold. The investment cannot be avoided if the merchant desires to have the merchandise available in an adequate range of sizes, colors and styles.

This invention utilizes some of the features of the invention illustrated and described in my copending application Ser. No. 392,831, led Aug. 28, 1964, the disclosure in said application being incorporated herein by reference. In certain forms of the invention illustrated herein there are utilized features of Patents 2,883,669, 2,885,683 and 3,134,983, to which reference is made.

It is a principal object of this invention to provide improved tailored summer and winter cap constructions which decrease the number of sizes required to fit all of the head sizes in the major size classifications of mens, boys, and junior boys sizes.

It is another object of the invention to provide tailored sum-mer and winter cap constructions which can be manufactured at reduced unit costs and tailored summer and winter cap constructions that are attractive in appearance and keep their appearance during use.

It is another object of the invention to provide improved cap construction which can be manufactured at reduced cost and utilizing fewer operations and pieces.

Other and further objects are those inherent in the invention herein illustrated, described and claimed and will be apparent as the description proceeds.

To the accomplishment of the foregoing and related ends, this invention then comprises the features hereinafter, fully described and particularly pointed out in the r structed of cloth fabric,

ICC

claims, the following description setting forth in detail certain illustrative embodiments'of the invention, these being indicative, however, of but a few of the various ways in which the principles of the invention may be employed.

The invention is illustrated with reference to the drawings in which:

FIGURE 1 is a side elevational view of a cap made according to the present invention and which does not have ear flaps, and which is therefore primarily suitable when ear protection is not required;

FIGURE 2 is a sectional view taken along the line and the direction of arrows 2 2 of FIGURE 1;

FIGURE 3 is an enlargement of a portion of the sectional view shown in FIGURE 2, being that portion shown in the dotted circle of FIGURE 2 and marked Area of FIGURE 3;

FIGURE 4 is a fabric composite, ent invention;

FIGURE 5 is a sectional view of the same laminated composite, taken in the direction of arrows 5-5 of FIG- URE 4;

FIGURE 6 is a sectional View in the direction of arrows 6 6 of FIGURE 7 and shows a strip of the laminated composite strip of FIGURE 4 folded into a transverse U-shaped channel configuration;

FIGURE 7 is a side elevational View of the channel shown in FIGURE 6 and is as though viewed in the direction of a-rrow 7 of FIGURE 6;

FIGURE 8 is an enlargement of the sectional view shown in FIGURE 2, being that portion shown within the circle and marked Area of FIGURE 8;

FIGURE 9 is a fragmentary side elevational view of the sidewall of the lcap being that portion shown within the rectangular area marked Area of FIGURE 9 shown on FIGURE l;

FIGURE l0 is a side elevational View of another cap of the present invention in this instance provided with ear flaps;

FIGURE 11 is a rear elevational view of the cap shown in FIGURE 10, as though viewed in the direction of arrows 11-11 of FIGURE 10;

FIGURE 12 is a sectional View taken along the lines and in the direction of arrows 12-12 of FIGURE 10 and is much enlarged as compared to the side shown in FIGURE 10;

FIGURE 13 is a fragmentary View of the sidewall of the cap shown in FIGURE 10, greatly enlarged, bein-g the area illustrated within the dotted lines marked Area of FIGURE 13 as appears on FIGURE l0; and

FIGURE 14 is a rear elevation of a slightly modified embodiment of the invention, vbeing similar to FIG- URE 11.

In general it may be said that the caps of the present invention have certain portions of t-he cap, i.e. the visor (or bill), the forehead portion (or front) and the top, made of non-elastic materials, whereas the remainder of the cap, namely the sidewall-rearwall portions and the ear aps (where used) are of elastic material capable of 10% to 20% stretch in a direction measured around the head size at the head size location. Thus for those parts of the cap which are non-elastic (the visor of the cap, and for the front wall of the cap, i.e. the forehead portion, which is attached to the rear curved edge of the visor, and for the top of the cap), these parts of the cap are consuede, leather or such line, or Aother materials which are not considered elastic. Thus the visor of the cap, the front wall (forehead portion), that is to say the portion which is attached to all or most of the rear curved edge of the visor and the top of the cap may plan View of a multiple-ply laminated utilized as one of the parts in the presdimension to 20% be of Iordinary materials such as woven cloth, plastic coated cloth, artificial leather, leather, suede and such like materials, which are not commonly regarded as being elastic (i.e. they do not stretch very much).

However, the other portions lof the cap, namely the band of material forming the sidewall and rearwall, the trimming at the lower edge of this sideWall-rearwall band, the ear ap (where used) and the bindings of these parts and the stitching by which these parts are assembled, are made of materials which are capable of stretching in the direction of measurement around the sides'and rear of the head. Therefore, pursuant this invention, these portions of the cap are constructed of materials which have resiliency (i.e. they are able to stretch) to increase their when measured in the direction circumferentially around the head from approximately above the left front temple, thence rearwardly along the left side of the head, thence around the rear of the head and along the right side of the head to a corresponding position about the front right temple. This measurement will, for convenience, be called the sidewall-rearwall portion of the cap and the measurement is called dimension SRS (for sidewall-rearwall-sidewall).

The chosen elastic materials which constitute'all portions of the cap below the top and to the rear of the visor and front wall, when constructed pursuant this invention, are made of materials which are then capable of stretching resiliently along the sidewall-rearwall portions of the cap. A stretch from 10% to 20% of length is desirable. This resiliency (or elasticity) need not produce a strong returning tension force (which might be uncomfortable) but is should be a mild but positive resilient returning force capable of returning these portions of the cap to their minimum (not-stretched) size, when no outward pressure (i.e. hoop-tension due to the wearers head) is exerted on the inside of the cap.

-Referring now to FIGURES 1-9, in these figures there is illustrated one illustrative embodiment of the invention. Referring to FIGURE 1 there is shown the visor 10 (which can be long or short as beits the design) and the frontwall portion 11. These are attached together at line 11A in the usual way. The visor is of moderately stiff material (or may contain a stiener). The frontwall 11 can be capableof some exure and slight elasticity, so as to conform to the forehead of the wearer when the cap is worn. The lower edge 11A -of frontwall portion 11 is attached to the curved rear portion 10B of visor 10 by stitching or other mode of fastening. The upper edge 11B of the frontwall portion 11 is attached to the curved front edge portion yof the top 12, which like the frontwall 11, can be of material which is capable of bending but is not stretchy. The top 12 is normally lined and may contain an innerliner or top stiffener.

These three portions of the cap (i.e. visor 10, frontwall 11 and top 12) when joined together, produce the framework yof the cap and they establish its lines and style, and add to a modish appearance of the cap, when worn. They help the cap keep its shape.

The rear terminal side edges 11C of the frontwall (of which the left such edge 11C is shown in FIGURE 1) is the line of attachment for the sideWall-rearwall portion generally designated 15, which stretches from this edge 11C and thence entirely along the left side of the wearers head and around the rear of the head and forwardly on the right side of the head to a corresponding line of attachment at the far side edge 11C (not shown) of the frontwall portion 11. The material used for the construction of this sdeWall-rearwall portion 15 of the cap is, pursuant this invention, a composite laminate composed of three layers 15A, 15B and 15C, as illustrated in FIGURES 2, 3 and 8. Each of these layers of material is of a material which is elastic (i.e. it will stretch) 10% to at least in the direction of measurement of line SRS (abbreviation of sidewall-rearwall-sidewall) around 4 the head of the wearer, as shown in FIGURE 1. This dimension line SRS is also shown in FIGURE 9.

Normally the outer layer 15A and the inner layer 15C of the composite 15 are composed of fabrics whereas the middle layer (or inside layer) 15B is composed of a very lightweight compressible, stretchy plastic, rubber, or other such foam-type lightweight elastic material. Layer 15B also affords insulation value. Porous plastic foam is preferred, but porous foam rubber, and certain other similar materials may be used. It is preferable and usually most economical and best to use a lightweight stretchy plastic foam for the middle layer 15B. This layer is highly compressible in thickness.

For the inner layer 15C it is preferable to use a tricoknit fabric which may be of rayon, nylon -or cotton or blends of synthetic materials. These fabrics are knitted, they are attractive, durable, and what is important for the present invention they tion of measurement -of the fabric. For the uses of this invention, the stretchiness in the direction of dimension SRS is desired, but stretchness in a direction transverse to the direction SRS, where this is inherent in the fabric, is not undesirable. Therefore, pursuant this invention, it is preferable to use 'for the inner layer 15C a tricoknit fabric or equivalent finely knitted elastic fabric.

For the outer layer 15A the desired elasticity in the direction of dimension SRS can easily be achieved by using a knitted fabric, such as a rib-knit or Swiss-knit fabric with the ribs vertical (i.e. at right angles or approximately right angles) to the direction-of-stretch that is with the ribs of the fabric transverse to dimension SRS. A fairly coarsely rib-knitted fabric at 15A with ribs vertical or nearly so, gives good results and has an attractive styling. For summer caps a lightweight rib-knitted fabric for the outer layer 15A will give good service, or tricoknit fabric may be used for the outside layer 15A.

The three layers 15A, 15B and 15C are secured by interlayer adhesion, either by the use of adhesives or by tackiness which is induced in one or the other of the fabrics at interface contact therebetween. Where plastic foam sheeting constitutes the middle layer 15B, the knitted fabrics 15A and 15C can be easily adhesively secured thereto by a process of heat lamination. To do this the middle plastic foam layer 15B is carried upon a suitable belt support and has its upper surface slightly heated, suicient only to render the upper surface of layer 15B (while on the belt) very slightly tacky due to slight melting of the plastic at the surface. Then, one of the layers 15A (or 15C) is sheeted onto such heated (and slightly tacky) upper surface of the plastic layer, and as the plastic cools the adhesiveness leaves the interlayer junction, and adhesion is accomplished. Then the plastic layer with one of the layers 15A (or 15C) attached to it is turned over and is processed in exactly the same way on the opposite side and the other layer 15C (or 15A) is similarly adhered. This process does not set the plastic foam layer 15B and does not interfere with the elasticity of layers 15A and 15B. Consequently the composite 15 remains entirely elastic, at least in the direction of dimension SRS. The composite 15 is compressible in thickness especially through the plastic foam layer 15B. The resultant multi-layer composite 15, being composed of fabric outerlayer 15A, the middle layer 15B and the fabric inner layer 15C, all 'being stretchy in at least the direction SRS, when applied to the cap, can then be cut and processed in the formation of the cap.

The upper edge 15B of this multiple layer composite 15 is then attached to that portion of the circumference of the top 12 which it abuts, by a line of stitching illustrated in FIGURES 2. and 3. This line of stitching need not be elastic, since the edge of top 12 is not elastic. As shown in these figures, the cap top 12 is provided with a liner 12L which can be quilted to an inner liner or stiffener 12F. The edge of the top 12-12L (and 12F where used) is then secured to the folded upper edge 15U of have good elasticity in each direc-` the sidewall-rearwall portion 15, by a line of stitching at 16. The inturned edges of the top 12 and sidewall portion 15, are then trimmed by a binding 17 which is secured in place 'by lan inside line of stitching at 18 which need not be stretchy. This construction is shown in FIGURE 3. It is noted parenthetically, that the thickness dimension of the fabrics and the thickness of the seams are exaggerated in all of the drawings, as for example in FIGURE 3. At the seams, the layer 15B is much compressed, almost to a .few thousandths of an inch, due to the pull of the stitching and easy compressibility of layer 15B.

The yfront part of the sideWall-rearwall-sidewall portion 15 may be secured by a blind stitching or an exposed stitch at line 11C, FIGURE 1 (and a similar line of stitching on the opposite side of frontwall 11 of the cap). For caps not having ear aps, the lower edge 15L of the sidewall 15 is trimmed by -a folded strip of composite illustrated in FIGURES 2 and 4-7. The trim is in the form of a folded strip generally designated 20, which is composed of a relatively thick layer of spongy resilient material 20A, adhesively secured to al resilient strip 20B which is elastic, i.e. it has stretchiness in the direction of its length, i.e. in the direction of arrow 21 of FIGURE 4. The fabric 20B is outside when the composite strip is folded to the configuration shown in FIGURES 2, 6 and 7, and can Very desirably be made of a bias cut woven fabric of rayon, nylon or other similar materials, adhesively secured to a sponge plastic or sponge rubber layer. The construction of this strip of material is illustrated and described in my copending application Ser. No. 392,831, filed Aug. 28, 1964, now Patent 3,247,523, granted Apr. 26, 1966, the disclosure of which application is incorporated herein by reference. As shown in FIGURES 6 and 7, when the strip is folded to the U- shaped channel configuration it may be stretched in the direction of the length of the strip (ie. arrow 21)'by ian amount 10% to 20% of the relaxed dimension. This folded strip is then secured to the lower edge L of the sidewall-rearwall portion 15 of the' cap by a line of stitching at 22. The line of stitching at 22 is elastic, i.e. it will stretch in the direction of the line of stitching. The folded piece 20 is applied to the edge 15L without stretching the strip and without stretching the lower edge 15L of the sidewall 15, and the line of elastic thread stitching 22 is then applied, but said line of stitching is, as aforesaid, made of a construction so as to be stretchy in the direction of the line of stitching. This can be accomplished by using an elastic thread such as dual duty softleft nylon cord cotton wrapped thread or similar elastic thread, which has a sufficient stretchiness when it is stitched, so that the line of stitching will not impair the elasticity which is otherwise possible in the materials 15 and 20 which are stitched together. Another way by which the elasticity of the wall 15 and binding 20 in the direction of dimension SRS in the cap may be kept unimpaired, especially the portion of wall 15 near and at the lower edge 15L, with the binding 20 on it, is to stretch the lower edge 15L and also stretch the binding 20 in the direction of the dimension SRS of the cap, 'before they are stitched together at 22 and 'when thus stretched the stitching 22 is done with ordinary thread. After stitching thus, the resiliency of the sidewall 15 especially at and `near its lower edge 15L, and the resiliency of the binding 20 both in the direction of the dimension SRS, will be such as to pull back, when tension is released, and in so doing the stitches 22 (if done with ordinary thread) will be loosened a little, but since the two pieces were stretched initially when they were stitched, the stitching itself will not thereafter impair subsequent stretching in the direction of the dimension SRS.

As a result of the construction just described, the lower edge 20, has a soft feel and due to its natural tendency 'to stretch in the direction of arrow 21, the edge 20 will provide a soft resilient trim to the lower edge of the sidewall. If desired, the edge 20* can bestretched a little (but not to its maximum) when being applied to the lower edge 15L of the sidewall-rearwall portion 15 (which is not stretched) and then stitched at 22. When this is done, after stitching 22 is completed,rthe tendency of the'trim strip 20 will be to return to its relaxed position and this will cause the entire portion 20 to 'be drawn inwardly a little as a hoop with reference to lower edge 15L of the cap. It will be noted that the lower edge 15L terminates only slightly below the line of stitching 22, and therefore there is a hollow space 20H within the trim 20 which gives a soft cushion effect.

In any event, the construction shown in FIGURES 1-9, provides a sidewall-rearwall portion 15 of the cap which is resilient in the direction of the dimension SRS and when it is not stretched it will have a relaxed dimension as illustrated in FIGURES 1 and 9, but it is capable of stretching to the dimension shown in dotted lines in FIGURE 1, also see FIGURE 9, when worn by a person having a headsize slightly larger than the head-size provided by the cap in its relaxed conditionl As a result, this construction provides a cap of tailored appearance, which will, however, be able to fit two or more different sizes, with equal comfort and modish styling. It will be noted that the frontwall 11, visor 10 and top 12 determines the configuration and lines of the cap, and as these cap portions do not stretch appreciably, the upper portion of the sidewall 15, at the edge 15B, will not be stretched, but will keep a good shape, and stand out from the head of the wearer to a certain degree, thereby avoiding undesirable roundness in appearance of the cap.

Referring now to the construction shown in FIGURES lO-l3 in this exemplification of the invention, there is provided an ear flap for protecting the ears of the wearer. This construction is preferred as a tailored winter cap. The construction of the upper portion of the cap, shown opposite the bracket 30 in FIGURE 10 can be identical with that shown and described with reference to FIG- URES 1 9, except that at the lower edge of sidewall-rearwall portion 15 the finish 20 (of FIGURES 1-9) is omitted and instead there is provided the ear flap attachment according to FIGURE 12. In FIGURE 12 the portion opposite the bracket 30 is the sidewall-rearwall portion 15, and can correspond to that shown in FIGURES 1 9, being composed of an outer layer 15A, a middle layer 15B and an inner' layer 15C, being elastic and stretchy in the directionof the dimension SRS of FIG- URE l0, in exactly the same way as that shown in FIG- URE 1. However, where in FIGURE l the lower edge 15L has attached to it the composite finishing strip 20, in the instance of the construction of FIGURES 10-13 and FIGURE 14 the sidewall-rearwall portion 15 is initially cut with a larger vertical dimension, so that the entire wall can be folded up at lower fold line 15F. The fold is made inwardly and upwardly so that the composite finishing strip 20 (which folds over the edge 15L and is secured by stitching 22 in exactly the same way as in FIGURE 1) now lies within the wall 15 of the cap, on the inside, and is held in an upwardly directed position by the stitching 34 which maintains fold 15F. This stitching 34 also serves to secure the upper folded edge of a foldedover binding 35, which serves as a trim strip for the ear ap portion 31 and as a means for attaching the upper edge of the ear ap 31 to the upper portion 30 of the cap. The lower free edges of the binding 35 are attached by stitching 36 to the opposite outer faces of the outside and inside layers of the ear flap composite, which is generally designated 37. This ear flap portion 37 may be constructed in several ways. According to one way it is composed of an outer fabric layer 37A, a middle layer 37B which can be of good insulating value and is compressible in thickness, and an inner fabric layer 37C. The inner fabric 37C can be a brushed surface fabric as for example a flannel type fabric, since this surface is against the ears of the wearer when the ear aps are in the down position. The outer fabric 37A can, for style, be the same as the outer fabric 115A, if desired, or can be different. Three layers 37A, 37B and 37C are adhesively attached together and they can be attached in the same manner as previously described with respect to the construction of the three layer composite 15, when the middle layer 37B is of plastic foam sheeting (which is very desirable because of its lightweight, high insulating value and stretchiness), the inner layer 37C and the outer layer 37A can be attached thereto by heating process and laminating, as previously described.

The ear ap is attached to a head band which is composed of the folded upper binding 35, secured -by the stitching 36. This binding is in the form of a band that -goes entirely around the head, and is made of a size corresponding to the largest size to which the upper portion of the cap (shown opposite the bracket 30 in FIGURES l() and 12) will be stretched when worn by a wearer having a large head size.

Pursuant this invention the multiple layer ear flap portion 37, therefore, need not be resilient per se, but may be resilient (i.e. elastic in direction of dimension F) or not elastic. When it is not made elastic, it is desirable to insert at the rear of the ear ap assembly a resilient gusset 38, which is constructed in accordance with Patents 2,883,669 and/or 2,885,683, and when such a resilient gusset, having resiliency in the direction of arrow 39 is used in the ear flap portion 31, such gusset will cause the ear flap portions at each side of the head to be drawn snugly around the head and against the ears of the wearer. When applying an ear flap portion, which is constructed of non-resilient composite 37, the previously made upper portion of the cap 30, is stretched to its maximum size at the fold 15F and elastic inband 20 prior to the time that the line of stitching at 34 is applied, and after stitching 34 (which may in this mode of attachment be of ordinary thread) the tension which had stretched the wall 15 and inband 20 is relaxed and the stitching will therefore be then drawn in by the hoop tension of the sidewallrearwall portion of the cap 15 where it is folded at 15F, due to the elasticity of the portion 15 at this level and due to the elasticity of composite 20 which was also stretched. As an alternative, the stitching at 34 may be made of resilient thread. The binding at 20, being also resilient in the direction of its length, tends to act as a resilient hoop, and will cause the cap to be drawn inwardly at the level of bracket 32, when the cap is relaxed. The lower edge 37L of the ear flap portion 31 can be bound by a folded strip of material of exactly the same construction as illustrated and described with reference to FIGURES 4-7, and used at 20 in FIGURES 2-8 and FIGURE 12. This resilient folded strip generally designated 40 is folded over the lower edge 37L and secured |by a line of stitching 41 which is preferably done with stretchy thread. The lower edge 37L does not extend entirely into the folded strip thereby leaving a hollow space at 40H. The effect of the resilient lower trim and binding 40 will be to cause the lower edge of the ap portion 31 to be drawn inwardly towards the cheek and back of the neck of the wearer. If desired, and especially where the resilient gusset 38 having resilience in the direction 39 is used, an ordinary bias strip binding may be substituted at 40 for the ear ap portion 31.

As shown in FIGURE 13, when the ear flaps are made of materials not inherently elastic and elasticity is provided by gusset 38, the portions 30 of the sidewall 15 and the joinder position at 32, between the sidewall and the ear flap portion 37 will have a greater degree of resiliency in the direction of the dimension SRS around the cap then will the ear flap portion per se. Consequently, when the ear ap portion 37 per se is of non-resilient material (and the resilient gusset 38 is used) the upper edge of the ear ap is desirably made of a dimension equalling the largest size to which the lower folded edge F of the sidewall 15 can` be stretched by the user-having a large head and the upper part of the cap (ie. wall 15) is. stretched out to this invention,

this size before sewing at 34 to binding 35. Then when the cap is in a relaxed condition the elastic effect of sidewall-rearwall portion 15 of the cap (especially at 15F and also due to elastic inband 20) will cause a certain amount of compression of the dimension of 'binding 35 on the upper edge of the ear flap portion 37.

According to a second mode of construction, pursuant the ear ap portion 37 may, if desired, be constructed of material which is inherently elastic at least in a direction around the head, that is to say, in the direction of the dimension line F shown in FIGURES l0, l1 and 14. For example, according to this embodiment of the invention the outer and inner layers 37A and 37C may be constructed of the same or different elastic fabrics, for example, tricoknit fabrics. Thus the `outer layer 37A might be a tricoknit fabric having one color and finish and inner layer 37C a different color and finish. Normally, the inner layer 37C will be of such fabric such as to be quite comfortable to the ears of the wearer. These fabrics are applied so as to be stretchy in at least the direction of dimension F, and they can be applied in 11n-stretched condition to opposite faces of a plastic foam middle layer 37B, 'by the heat-adhesion process previously described. This provides a composite laminate 37, which is compressible in thickness (especially in respect to middle layer 37B) and which will stretch in the direction of dimention F. When such a ycomposite is used, for construction the ear flaps, the resilient gusset 38 may be eliminated or made smaller. FIGURE 14 shows the gusset eliminated. In such instance the lower binding 40 may, if desired, be placed on under slight tension, so that it tends to apply a hoop tension along its length, and pull the lower edge of the ear ap portion 31 a little more snugly against the back of the head and the cheeks of the wearer, then would -otherwise be achieved, acting something like a resilient drawstring along the lower edge. When the ear ap portion 37 is thus composed of such a stretchy three layer laminate, the rbinding 35, by which it is attached to the sidewall 15 at stitching 34, is also made stretchy in the direction of the length of that edge which is to say in the direction of the lines of stitching 34 and 36. The stitchings 34 and 36 are preferably thin made of stretchy thread but can be made of yordinary thread if the parts are stretched, then stitched while stretched and then relaxed. Assuming the use of stretchy thread such elastic -binding 35 is then sewed to the upper edge of the three layer laminate 37 by means of a stretchy thread 36 while relaxed. By similarly stitching the folded upper edge of such elastic binding 35 (while relaxed) is attached with stretchy thread 34, to the lower folded edge 15P of the sidewall 15. Hence by applying the stitching with stretchy thread while the binding 35, the sidewall-rearwall portion 15 and the ear ap portion 37 are all in a relaxed condition, it follows that all portions of the cap structure oppos1te respectively the brackets 30, 32 and 31 in FIGURES l2 and 14, will be of material and so constructed as to have the ability when placed under tension of stretching in the direction of the dimensions SRS and F, as shown in FIGURE 14. At the same time the resilient in'band portion 20 adds resiliency and also acts as a soft ller. The net effect of such construction is that the cap can easily resiliently expand to it two or more head sizes larger than its relaxed size, while still retaining a very good appearance. Such construction, where the resilient insert 38 is eliminated, is shown in FIGURE 14. If desired when using inherently resilient composite 37 for the ear flaps (FIG- URE 14) the insert 38 may still be retained but may be made somewhat narrower than as shown in FIG- URE ll.

For purposes `of easy nomenclature headsize shall be considered as the size around the head at the approximate level of the lower edge of wall 15 and line 11A in the embodiment of FIGURES 1 9 and at the approximate level of the lower edge 15P of wall 15 and line 11-A of the embodiment of FIGURES 10-13 and FIGURE 14.

As many widely apparently different embodiments of this invention may be made without departing from the spirit andscope thereof, it is lto be understood that I do not limit myself to the specific embodiments disclosed herein.

What is claimed is:

1. A cap of tailored construction comprising a shell adapted to embrace the upper part of the head above the headsize level, including a forehead portion having an upper edge, side edges and a lower edge at the headsize lever, a top, and a sidewall-rearwall band adapted to cover the sides and rear portions of the head, said sidewall-rearwall band having an upper edge, a lower edge and front edges, the front edges of said sidewall-rearwall band being attached to the side edges of the forehead portion, a visor centered in respect to the forehead portion and having its rear edge attached to the lower edge of the forehead portion, the upper edge of the sidewall-rearwall band being attached to the top, said visor, forehead portion and top being of relatively inextensible materials, said sidewall-rearwall band having inner and outer fabric plys and an intermediate soft compressible ply adhered together forming a composite of plys of material, all of which plys are elastic at least in the longitudinal direction of said sidewall-rearwall band between its attachments to the forehead portion of the cap, the lower margin of said sidewall-rearwall band being folded upward and inward forming at the fold a lower edge adapted to coincide with the headsize level, said upward and inward folded margin terminating 4as an upwardly directed terminal edge inside the cap shell and slightly above said lower edge, a cushion band comprising an inverted U- shaped fold of material, elastic means marginally securing said cushion band t-o said terminal edge, said cushion band being transversely compressible and stretchable in the direction of its length, and an ear flap assembly for the cap comprising a main ear ap portion having inner and outer fabric plys and an intermediate compressible ply adhered together forming plys of material, at least a portion of the ear ap assembly being elastic so as to permit it to stretch in -a direction parallel to the longitudinal direction of the sidewall-rearwall band, upper and lower elastic edgings for said main ear ap portion, at least the upper elastic edging comprising a fabric strip which is folded along its length having proximate edges of the strip enclosing proximate upper margins of the main ear ap portion, elastic means securing said upper elastic edging in such position, said main ear flap portion and elastic edgings and means for securing when al1 assembled together adapted to be extensible at least in the direction around the head of the wearer, the fold of the edging on the upper edge of said main ear ap portion being spaced I form the `outer and upwardly from the upper edge of said main ear ap p0rtion, elastic means securing said edging to said upward and inward folded margin of the cap.

2. The cap of claim 1 further characterized in that said outer and inner plys of the main ear flap portion are stretch fabric.

3. The cap of claim 1 further characterized in that said composite `of plys of material adhered together and of which said sidewall-rearwall band and main ear ap portion are made includes a ply of elastic compressible foam material between plys of knitted elastic fabrics which inner surfaces of the finished cap.

4. The cap of claim 1 further characterized in that the stretch cushion band is secured to the sidewall-rearwall band while both are stretched and the assembly is then relaxed.

5. The cap of claim 1 further characterized in that under conditions of no stress the cushion band is normally shorter than the terminal edge of the sidewall-rearwall band when the latter is not stretched and said cushion band elastically assumes a head band size slightly less than would normally be assumed by the terminal edge of the Sidewall-rearwall when the latter is not stressed.

6. The cap of claim 1 further characterized in that the ear ap assembly is a continuous band adapted to completely encircle the head, the vertical dimension of said band is at -a minimum where it is attached adjacent the rear e ge of the visor of the cap and increases gradually downward to a maximum vertical dimension about the lower edge of said sideWall-rearwall band.

References Cited UNITED STATES PATENTS 1,523,000 l/1925 Clark 2-183 1,681,006 -8/1928 Merton 2-195 1,717,169 6/ 1929 Pekowsky 2-19'5 2,052,123 8/1936 Adamson 2-195 2,820,226 1/1958 Topiel et al. 2`18l 2,885,683 5/1959 Lipkn 2-172 3,089,147 5/1963 Zimmerman 2-1'97 FOREIGN PATENTS 561,581 10/1957 Belgium. 669,237 8/ 1963 Canada.

21,870 3/ 1905 Great Britain. 530,502 12/1940V Great Britain. 848,628 9/ 1960 Great Britain.

JORDAN FRANKLDI, Primary Examiner. G. KRIZMANICH, Assistant Examiner. 

1. A CAP OF TAILORED CONSTRUCTION COMPRISING A SHELL ADAPTED TO EMBRACE THE UPPER PART OF THE HEAD ABOVE THE HEADSIZE LEVEL, INCLUDING A FOREHEAD PORTION HAVING AN UPPER EDGE, SIDE EDGES AND A LOWER EDGE AT THE HEADSIZE LEVER, A TOP, AND A SIDEWALL-REARWALL BAND ADAPTED TO COVER THE SIDES AND REAR PORTIONS OF THE HEAD, SAID SIDEWALL-REARWALL BAND HAVING AN UPPER EDGE, A LOWER EDGE AND FRONT EDGES, THE FRONT EDGES OF SAID SIDEWALL-REARWALL BAND BEING ATTACHED TO THE SIDE EDGES OF THE FOREHEAD PORTION, A VISOR CENTERED IN RESPECT TO THE FOREHEAD PORTION AND HAVING ITS REAR EDGE ATTACHED TO THE LOWER EDGE OF THE FOREHEAD PORTION, THE UPPER EDGE OF THE SIDEWALL-REARWALL BAND BEING ATTACHED TO THE TOP, SAID VISOR, FOREHEAD PORTION AND TOP BEING OF RELATIVELY INEXTENSIBLE MATERIALS, SAID SIDEWALL-REARWALL BAND HAVING INNER AND OUTER FABRIC PLYS AND AN INTERMEDIATE SOFT COMPRESSIBLE PLY ADHERED TOGETHER FORMING A COMPOSITE OF PLYS OF MATERIAL, ALL OF WHICH PLYS ARE ELASTIC AT LEAST IN THE LONGITUDINAL DIRECTION OF SAID SIDEWALL-REARWALL BAND BETWEEN ITS ATTACHMENTS TO THE FOREHEAD PORTION OF THE CAP, THE LOWER MARGIN OF SAID SIDEWALL-REARWALL BAND BEING FOLDED UPON AND INWARD FORMING AT THE FOLD A LOWER EDGE ADAPTED TO COINCIDE WITH THE HEADSIZE LEVEL, SAID UPWARD AND INWARD FOLDED MARGIN TERMINATING AS IN UPWARDLY DIRECTED TERMINAL EDGE INSIDE THE CAP SHELL AND SLIGHTLY ABOVE SAID LOWER EDGE, A CUSHION BAND COMPRISING AN INVERTED USHAPED FOLD OF MATERIAL, ELASTIC MEANS MARGINALLY SECURING SAID CUSHION BAND TO SAID TERMINAL EDGE, SAID CUSHION BAND BEING TRANSVERSELY COMPRESSIBLE AND STRETCHABLE IN THE DIRECTION OF ITS LENGTH, AND AN EAR FLAP ASSEMBLY FOR THE CAP COMPRISING A MAIN EAR FLAP PORTION HAVING INNER AND OUTER FABRIC PLYS AND AN INTERMEDIATE COMPRESSIBLE PLY ADHERED TOGETHER FORMING PLYS OF MATERIAL, AT LEAST A PORTION OF THE EAR FLAP ASSEMBLY BEING ELASTIC SO AS TO PERMIT IT TO STRETCH IN A DIRECTION PARALLEL TO THE LONGITUDINAL DIRECTION OF THE SIDEWALL-REARWALL BAND, UPPER AND LOWER ELASTIC EDGINGS FOR SAID MAIN EAR FLAP PORTION, AT LEAST THE UPPER ELASTIC EDGING COMPRISING A FABRIC STRIP WHICH IS FOLDED ALONG TIS LENGTH HAVING PROXIMATE EDGES OF THE STRIP ENCLOSING PROXIMATE UPPER MARGINS OF THE MAIN EAR FLAP PORTION, ELASTIC MEANS SECURING SAID UPPER ELASTIC EDGING IN SUCH POSITION, SAID MAIN EAR FLAP PORTION AND ELASTIC EDGINGS AND MEANS FOR SECURING WHEN ALL ASSEMBLED TOGETHER ADAPTED TO BE EXTENSIBLE AT LEAST IN THE DIRECTION AROUND THE HEAD OF THE WEARER, THE FOLD OF THE EDGING ON THE UPPER EDGE OF SAID MAIN EAR FLAP PORTION BEING SPACED UPWARDLY FROM THE UPPER EDGE OF SAID MAIN EAR FLAP PORTION, ELASTIC MEANS SECURING SAID EDGING TO SAID UPWARD AND INWARD MARGIN OF THE CAP. 